Improving Tank Manufacturing Safety with Cameras

Large tank manufacturing can be a difficult process.  Welding together large pieces of formed metal to make round tanks and pressure vessels can be technically challenging.  Typically, manufacturers will implement automatic welding equipment that needs to be constantly monitored in order to ensure that it is operating as optimally as possible.  As automatic as most of the machines are on the market today, there still is a need for operators to monitor the weld process for a number of issues, namely:

• Adjusting the rotational speed of the tank components being welded;
• Adjusting the feed speed of the wire as it goes to the weld head;
• Adjusting the weld head for seam alignment because the tank metal components are not perfectly round.

Automatic Tank Fabrication

Often, operators are used to physically monitor the welding process directly at the weld site.  This can be a significant safety hazard, especially when using large column and boom welding equipment inside the tanks as the operators can be confined to tight spaces when monitoring the weld and be exposed to multiple toxic fumes.  A simple solution can be implemented to solve this problem: a Xiris XVC Weld Camera. This camera can be mounted on to the weld head allowing the operator can to monitor the welding process remotely, from a safe location outside the tank.

This Weld Camera solution was recently installed at a large tank manufacturer.  Prior to implementing the camera, the manufacturer had their operators monitor the weld process directly inside the tank.  Forced to lie flat beside the welding boom to be able to see the welding process as the tank rotated under them, the operators could potentially slip or fall and hit the boom, hot weld seam or bead.  In addition, the operators had to wear extensive personal protection equipment (PPE) and a heavy duty ventilation system had to be installed in order to remove smoke and fumes from the weld process and bring fresh air into the tank in order to protect staff from exposure.  By installing the Weld camera, the manufacturer avoided health and safety issues and made the work of welding a much more comfortable and appealing experience for the operators.

The Result

The customer decided to implement a Xiris XVC Weld Camera as part of their overall automation equipment upgrade.  In the words of one of their technicians, the Xiris camera was “the most important part of the upgrade” as it allowed, for the first time, the operator to monitor the welding process remotely.  Now, ventilation equipment is no longer required and the operator can sit in a chair outside of the tank, wear no protective equipment or ventilation equipment, and view a monitor, which  provides better visibility of the weld; allowing for better   control of the weld process.

For more information on how Xiris Weld Cameras can help monitor your weld processes, visit Xiris.com